Transfer Assembly: Reassembly

Special Tools Required

Driver, 40 mm I.D. 07746-0030100
Attachment, 35 mm I.D. 07746-0030400
Driver 07749-0010000
Oil seal driver attachment 07GAD-PG40100 or 07GAD-PG40101
Companion flange holder 07XAB-0010100
Attachment, 72 x 75 mm 07746-0010600

NOTE:

While reassembling the transfer assembly:
- Check and adjust the transfer gear tooth contact.
- Measure and adjust the transfer gear backlash.
- Check and adjust the tapered roller bearing starting torque.
Coat all parts with ATF during reassembly.
Replace the tapered roller bearing and the bearing outer race as a set if either part is replaced.
Replace the transfer drive gear and the transfer output shaft (hypoid gear) as a set if either part is replaced.

Select the 35 mm thrust shim if the transfer output shaft (hypoid gear) is replaced. Calculate the thickness of the 35 mm thrust shim using the formula, and select the shim from the table.

FORMULA: A/100 - B/100 +C = X

A: Number on the existing transfer output shaft (hypoid gear)

B: Number on the replacement transfer output shaft (hypoid gear)

C: Thickness of the existing 35 mm thrust shim

X: Thickness needed for the replacement 35 mm thrust shim

NOTE: The number on the transfer output shaft (hypoid gear) is shown in 1/100 mm.

Fig 1: Adjusting Tapered Roller Bearing Starting Torque

Courtesy of AMERICAN HONDA MOTOR CO., INC.

Select No. M 35 mm thrust shim of 1.08 mm (0.043 in.).

THRUST SHIM, 35 mm

THRUST SHIM SPECIFICATION

Shim No.	Part Number	Thickness
A	41361-PS3-000	0.72 mm (0.028 in.)
B	41362-PS3-000	0.75 mm (0.030 in.)
C	41363-PS3-000	0.78 mm (0.031 in.)
D	41364-PS3-000	0.81 mm (0.032 in.)
E	41365-PS3-000	0.84 mm (0.033 in.)
F	41366-PS3-000	0.87 mm (0.034 in.)
G	41367-PS3-000	0.90 mm (0.035 in.)
H	41368-PS3-000	0.93 mm (0.037 in.)
I	41369-PS3-000	0.96 mm (0.038 in.)
J	41370-PS3-000	0.99 mm (0.039 in.)
K	41371-PS3-000	1.02 mm (0.040 in.)
L	41372-PS3-000	1.05 mm (0.041 in.)
M	41373-PS3-000	1.08 mm (0.043 in.)
N	41374-PS3-000	1.11 mm (0.044 in.)

Select the 35 mm thrust shim if the tapered roller bearing on the transfer output shaft (hypoid gear) is replaced. Measure the thickness of the replacement bearing and the existing bearing, and calculate the difference of the bearing thickness. Adjust the thickness of the existing 35 mm thrust shim by the amount of difference in bearing thickness, and select the replacement 35 mm thrust shim from the table on step 1.
Install the 35 mm thrust shim (A) on the transfer output shaft (hypoid gear) (B), then install the tapered roller bearing (C) with the special tools and a press.

Fig 2: Installing Tapered Roller Bearing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Place the tapered roller bearing (A) on the bearing outer race of the companion flange side of the transfer housing.

Fig 3: Placing Tapered Roller Bearing (A) On Bearing Outer Race Of Companion Flange Side Of Transfer Housing
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the new oil seal (B) on the transfer housing with the special tools and a press.
Install the transfer output shaft (hypoid gear) (A) in the transfer housing (B). Do not install the transfer spacer on the transfer output shaft.

Fig 4: Installing Transfer Output Shaft (Hypoid Gear) (A) In Transfer Housing (B)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the companion flange (A), conical spring washer (B), and locknut (C) on the transfer output shaft (hypoid gear) (D). Do not install the O-ring and back-up ring on the transfer output shaft.

Fig 5: Installing Companion Flange (A), Conical Spring Washer (B), And Locknut (C) On Transfer Output Shaft (Hypoid Gear) (D)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.
Tighten the locknut while measuring the starting torque so the starting torque is within 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 lbf.in).
NOTE: Do not stake the locknut in this step.

Tightening torque: 108-294 N.m (11.0-30.0 kgf.m, 79.6-217 lbf.ft)

Starting torque: 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.)

Fig 6: Installing Transfer Housing In Bench Vise With Soft Jaws
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Apply Prussian Blue to both sides of the transfer drive gear teeth lightly and evenly.
Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer drive gear/shaft assembly (C) in the transfer housing (D).

Fig 7: Installing Tapered Roller Bearing (A), Thrust Shim (B), And Transfer Drive Gear/Shaft Assembly (C) In Transfer Housing (D)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the transfer cover (E), and tighten the bolts. Do not install the O-ring on the transfer cover.
Rotate the companion flange several times to seat the tapered roller bearings.
Set a dial indicator (A) on the transfer companion flange (B); position dial indicator tip (C) on the direct extension of the bolt hole center (D).

Fig 8: Set A Dial Indicator (A) On Transfer Companion Flange (B); Position Dial Indicator Tip (C) On Direct Extension Of Bolt Hole Center (D)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the transfer gear backlash.
Standard: 0.06-0.16 mm (0.02-0.06 in.)
Remove the transfer cover, transfer drive gear/shaft assembly, and check the transfer drive gear tooth contact pattern.
CORRECT TOOTH CONTACT PATTERN

Fig 9: Checking Transfer Drive Gear Tooth Contact Pattern
Courtesy of AMERICAN HONDA MOTOR CO., INC.

INCORRECT TOOTH CONTACT PATTERN

Fig 10: Identifying Tooth Contact Patterns
Courtesy of AMERICAN HONDA MOTOR CO., INC.
If the measurement of the backlash is out of the standard, adjust the transfer gear backlash with the 35 mm thrust shim and recheck. Do not use more than two 35 mm thrust shims to adjust the transfer gear backlash.

If the transfer gear tooth contact is incorrect, adjust the transfer gear tooth contact with the 25 mm or 35 mm thrust shim. Do not use more than two shims of each thrust shim to adjust the tooth contact.

Toe Contact
Use a thicker 35 mm thrust shim to move the transfer output shaft (hypoid gear) toward the transfer drive gear. Because this movement causes the transfer backlash to change, move the transfer drive gear away from the transfer output shaft (hypoid gear) to adjust the transfer gear backlash as follows:
- Increase the thickness of the 25 mm thrust shim.
- Reduce the thickness of the 75 mm thrust shim by the amount of increase thickness of the 25 mm thrust shim.
Heel Contact
Use a thinner 35 mm thrust shim to move the transfer output shaft (hypoid gear) away from the transfer drive gear. Because this movement causes the transfer gear backlash to change, move the transfer drive gear toward the transfer output shaft (hypoid gear) to adjust the transfer gear backlash as follows:
- Reduce the thickness of the 25 mm thrust shim.
- Increase the thickness of the 75 mm thrust shim by amount of reduce thickness of the 25 mm thrust shim.
Flank Contact
Use a thinner thrust shim to move the transfer drive gear toward the transfer output shaft (hypoid gear).

Flank contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Heel Contact.
Face Contact
Use a thicker thrust shim to move the transfer drive gear away from the transfer output shaft (hypoid gear).

Face contact must be adjusted within the limits of the transfer gear backlash. If the backlash exceeds the limits, adjust as described under Toe Contact.

THRUST SHIM, 25 mm

THRUST SHIM SPECIFICATION

Shim No.	Part Number	Thickness
1.70	29411-P1C-000	1.70 mm (0.067 in.)
1.73	29412-P1C-000	1.73 mm (0.068 in.)
1.76	29413-P1C-000	1.76 mm (0.069 in.)
1.79	29414-P1C-000	1.79 mm (0.070 in.)
1.82	29415-P1C-000	1.82 mm (0.072 in.)
1.85	29416-P1C-000	1.85 mm (0.073 in.)
1.88	29417-P1C-000	1.88 mm (0.074 in.)
1.91	29418-P1C-000	1.91 mm (0.075 in.)
1.94	29419-P1C-000	1.94 mm (0.076 in.)
1.97	29420-P1C-000	1.97 mm (0.078 in.)
2.00	29421-P1C-000	2.00 mm (0.079 in.)
2.03	29422-P1C-000	2.03 mm (0.080 in.)
2.06	29423-P1C-000	2.06 mm (0.081 in.)
2.09	29424-P1C-000	2.09 mm (0.082 in.)
2.12	29425-P1C-000	2.12 mm (0.083 in.)
2.15	29426-P1C-000	2.15 mm (0.085 in.)
2.18	29427-P1C-000	2.18 mm (0.086 in.)
2.21	29428-P1C-000	2.21 mm (0.087 in.)
2.24	29429-P1C-000	2.24 mm (0.088 in.)

Remove the transfer cover (A), transfer drive gear/shaft assembly (B), 25 mm thrust shim (C), and tapered roller bearing (D) from the transfer housing (E) after adjusting the transfer gear backlash or transfer gear tooth contact.

Fig 11: Removing Transfer Cover (A), Transfer Drive Gear/Shaft Assembly (B), Thrust Shim (C), And Tapered Roller Bearing (D) From Transfer Housing (E)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 12: Installing Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the locknut (A), conical spring washer (B), and companion flange (C) from the transfer output shaft (hypoid gear) (D).

Fig 13: Removing Locknut (A), Conical Spring Washer (B), And Companion Flange (C) From Transfer Output Shaft (Hypoid Gear) (D)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Remove the transfer output shaft (hypoid gear) (A) from the transfer housing (B).
Install the new transfer spacer (C) on the transfer output shaft in the direction shown, and install them in the transfer housing.

Fig 14: Removing Transfer Output Shaft (Hypoid Gear) (A) From Transfer Housing (B)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Coat the threads of the locknut and transfer output shaft (hypoid gear) with ATF.
Install the companion flange (A), new O-ring (B), back-up ring (C), new conical spring washer (D), and new locknut (E) on the transfer output shaft (hypoid gear) (F). Install the conical spring washer in the direction shown.

Fig 15: Installing Companion Flange (A), O-Ring (B), Back-Up Ring (C), Conical Spring Washer (D), And Locknut (E) On Transfer Output Shaft (Hypoid Gear) (F)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then install the special tool on the companion flange. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 16: Securing Transfer Housing (A) In Bench Vise (B) With Soft Jaws, Installing Special Tool On Companion Flange
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Tighten the locknut while measuring the starting torque of the transfer driven gear.
Tightening torque: 108-294 N.m (11.0-30.0 kgf.m, 79.6-217 lbf.ft)

Starting torque: 1.15-1.71 N.m (11.7-17.4 kgf.cm, 10.2-15.1 lbf.in.)
NOTE:
- Rotate the companion flange several times to seat the tapered roller bearings, then measure the starting torque.
- If the starting torque exceeds 1.71 N.m (17.4 kgf.cm, 15.1 lbf.in.), replace the transfer spacer and reassemble the parts. Do not adjust the torque with the locknut loose.
- If the tightening torque exceeds 294 N.m (30.0 kgf.m, 217 lbf.ft), replace the transfer spacer and reassemble the parts.
- Write down the measurement of the starting torque: it is used to measure the total starting torque.
Remove the special tools.
Stake the locknut using a 3.5 mm punch.

Fig 17: Staking Locknut
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Install the tapered roller bearing (A), 25 mm thrust shim (B), and transfer drive gear/shaft assembly (C) in the transfer housing (D).

Fig 18: Installing Tapered Roller Bearing (A), Thrust Shim (B), And Transfer Drive Gear/Shaft Assembly (C) In Transfer Housing (D)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Temporarily install the transfer cover (E) without the O-ring, and tighten the bolts.
Secure the transfer housing (A) in a bench vise (B) with soft jaws, then rotate the companion flange several times to seat the tapered roller bearings. To prevent damage to the transfer housing, always use soft jaws or equivalent materials between the transfer housing and the vise.

Fig 19: Installing Transfer Cover (A)
Courtesy of AMERICAN HONDA MOTOR CO., INC.
Measure the total starting torque. Total starting torque is the figure + the transfer driven gear starting torque measured in step 27.
Total starting torque = 1.51-1.78 N.m (15.4-18.1 kgf.cm, 13.4-15.7 lbf.in) + Transfer Output Starting Torque Value (measured and written down in step 26 )
Remove the transfer cover.
If the measurement is out of standard, remove the bearing outer race (A) and 75 mm thrust shim (B) from the transfer cover (C). If the bearing outer race is press-fitted, remove the bearing outer race by heating the cover to about 212°F (100°C) with a heat gun (D). Do not heat the cover more than 212°F (100°C).
If the measurement is within the standard, go to step 37.

Fig 20: Removing Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.

Measure the thickness of removed 75 mm thrust shim, and select the new 75 mm shim.

THRUST SHIM, 75 mm

THRUST SHIM SPECIFICATION

Shim No.	Part Number	Thickness
AA	41401-PGV-000	1.52 mm (0.060 in.)
AB	41402-PGV-000	1.55 mm (0.061 in.)
AC	41403-PGV-000	1.58 mm (0.062 in.)
AD	41404-PGV-000	1.61 mm (0.063 in.)
AE	41405-PGV-000	1.64 mm (0.065 in.)
B	41402-PW8-010	1.67 mm (0.066 in.)
C	41403-PW8-010	1.70 mm (0.067 in.)
D	41404-PW8-010	1.73 mm (0.068 in.)
E	41405-PW8-010	1.76 mm (0.069 in.)
F	41406-PW8-010	1.79 mm (0.070 in.)
G	41407-PW8-010	1.82 mm (0.072 in.)
H	41408-PW8-010	1.85 mm (0.073 in.)
I	41409-PW8-010	1.88 mm (0.074 in.)
J	41410-PW8-010	1.91 mm (0.075 in.)
K	41411-PW8-010	1.94 mm (0.076 in.)
L	41412-PW8-010	1.97 mm (0.078 in.)
M	41413-PW8-010	2.00 mm (0.079 in.)
N	41414-PW8-010	2.03 mm (0.080 in.)
O	41415-PW8-010	2.06 mm (0.081 in.)
P	41416-PW8-010	2.09 mm (0.082 in.)
Q	41417-PW8-010	2.12 mm (0.083 in.)
R	41418-PW8-010	2.15 mm (0.085 in.)
S	41419-PW8-010	2.18 mm (0.086 in.)
T	41420-PW8-010	2.21 mm (0.087 in.)
U	41421-PW8-010	2.24 mm (0.088 in.)
V	41422-PW8-010	2.27 mm (0.089 in.)
W	41423-PW8-010	2.30 mm (0.091 in.)
X	41424-PW8-010	2.33 mm (0.092 in.)
Y	41425-PW8-010	2.36 mm (0.093 in.)
Z	41426-PW8-010	2.39 mm (0.094 in.)
ZA	41406-PGV-000	2.42 mm (0.095 in.)
ZB	41407-PGV-000	2.45 mm (0.096 in.)
ZC	41408-PGV-000	2.48 mm (0.098 in.)
ZD	41409-PGV-000	2.51 mm (0.099 in.)
ZE	41410-PGV-000	2.54 mm (0.100 in.)
ZF	41411-PGV-000	2.57 mm (0.101 in.)
ZG	41412-PGV-000	2.60 mm (0.102 in.)
ZH	41413-PGV-000	2.63 mm (0.104 in.)
ZI	41414-PGV-000	2.66 mm (0.105 in.)

Install the 75 mm thrust shim (A) in the transfer cover (B). If you heated the cover, let it cool to room temperature before installing the thrust shim.
Install the bearing outer race (C) in the cover. Use the special tools to seat the bearing in the cover.

Fig 21: Installing Bearing Outer Race (C) In Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.
After replacing the 75 mm thrust shim, recheck and make sure the total starting torque is within the specification.
Install the new O-ring (A) on the transfer cover (B), then install the cover on the transfer housing (C).

Fig 22: Installing O-Ring On Transfer Cover
Courtesy of AMERICAN HONDA MOTOR CO., INC.